Komatsu wa480 6 wheel loader service repair manual (sn a48001 and up)
1. August 2011 Copyright 2011 Komatsu
Printed in USA DataKom Publications Division
00-1
CEBM023001
Shop
Manual
WA470-6
WA480-6
WHEEL LOADER
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
SERIAL NUMBERS
WA470-6 A46001 and up
WA480-6 A48001 and up
WA470-6, WA480-6
4. FOREWORD SAFETY
WA470-6, WA480-6 00-3
12
SAFETY 00
SAFETY NOTICE 00
GENERAL PRECAUTIONS 00
Mistakes in operation are extremely dangerous. Read the
OPERATION & MAINTENANCE MANUAL carefully
BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the
precautions given on the decals which are fixed to the
machine.
2. When carrying out any operation, always wear safety
shoes and helmet. Do not wear loose work clothes, or
clothes with buttons missing.
● Always wear safety glasses when hitting parts with a
hammer.
● Always wear safety glasses when grinding parts with a
grinder, etc.
3. If welding repairs are needed, always have a trained,
experienced welder carry out the work. When carrying
out welding work, always wear welding gloves, apron,
glasses, cap and other clothes suited for welding work..
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before starting
work, hang UNDER REPAIR signs on the controls in
the operator's compartment.
5. Keep all tools in good condition and learn the correct
way to use them.
6. Decide a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke
while working.
PREPARATIONS FOR WORK 00
1. Before adding oil or making repairs, park the machine
on hard, level ground, and block the wheels or tracks to
prevent the machine from moving.
2. Before starting work, lower blade, ripper, bucket or any
other work equipment to the ground. If this is not
possible, insert the safety pin or use blocks to prevent
the work equipment from falling. In addition, be sure to
lock all the control levers and hang warning signs on
them.
3. When disassembling or assembling, support the
machine with blocks, jacks or stands before starting
work.
4. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
handrails, ladders or steps when getting on or off the
machine. Never jump on or off the machine. If it is
impossible to use the handrails, ladders or steps, use a
stand to provide safe footing.
PRECAUTIONS DURING WORK 00
1. When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen them slowly
to prevent the oil from spurting out. Before
disconnecting or removing components of the oil, water
or air circuits, first remove the pressure completely from
the circuit.
2. The water and oil in the circuits are hot when the engine
is stopped, so be careful not to get burned. Wait for the
oil and water to cool before carrying out any work on
the oil or water circuits.
IMPORTANT SAFETY NOTICE 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accom-
panying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first con-
sider safety, and take the necessary actions to deal with the situation.
WARNING! Never modify, weld, cut, or drill
on any part of a ROPS
structure. Doing so may
weaken the structure which
could lead to possible failure in
a rollover situation
5. FOREWORD SAFETY
00-4 WA470-6, WA480-6
3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
15. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical
generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the
machine.
6. FOREWORD GENERAL
WA470-6, WA480-6 00-5
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards
when inspecting disassembled parts.
STANDARD VALUE TABLE
This section explains the standard values for new machine and judgement criteria for testing, adjusting and
troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts
in troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.
TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
DIAGRAMS AND SCHEMATICS
This section has the foldout drawings for the machine.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
7. FOREWORD HOW TO READ THE SHOP MANUAL
00-6 WA470-6, WA480-6
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HOW TO READ THE SHOP MANUAL 00
VOLUMES 00
Shop manuals are issued as a guide to carrying out repairs.
They are divided as follows:
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series
Electrical volume: Each issued as one to cover all models
Attachment volume: Each issued as one to cover all models
These various volumes are designed to avoid duplication of
information. Therefore to deal with all repairs for any model,
it is necessary that chassis, engine, electrical and attachment
be available.
DISTRIBUTION AND UPDATING 00
Any additions, amendments or other changes will be sent to
your distributors. Get the most up-to-date information before
you start any work.
FILING METHOD 00
1. See the page number on the bottom of the page. File the
pages in correct order.
2. Following examples show how to read the page number:
Example:
10 - 3
Item number (10. Structure and Function)
Consecutive page number for each item
3. Additional pages: Additional pages are indicated by a
hyphen (-) and numbered after the page number. File as
in the example.
Example:
REVISED EDITION MARK 00
When a manual is revised, an edition mark (bcd…) is
recorded on the bottom outside corner of the pages.
REVISIONS 00
Revised pages are shown at the LIST OF REVISED PAGES
between the title page and SAFETY page.
SYMBOLS 00
So that the shop manual can be of ample practical use,
important places for safety and quality are marked with the
following symbols.
10-4
10-4-1
Added pages
10-4-2
10-5
Symbol Item Remarks
Safety
Special safety precautions are
necessary when performing the
work.
★ Caution
Special technical precautions or
other precautions for preserving
standards are necessary when per-
forming the work.
Weight
Weight of parts or systems.
Caution necessary when selecting
hoisting wire or when working
posture is important, etc.
Tightening
torque
Places that require special
attention for tightening torque
during assembly.
Coat
Places to be coated with adhesives
and lubricants etc.
Oil, water
Places where oil, water or fuel
must be added, and the capacity.
Drain
Places where oil or water must be
drained, and quantity to be
drained.
8. FOREWORD HOISTING INSTRUCTIONS
WA470-6, WA480-6 00-7
12
HOISTING INSTRUCTIONS 00
HOISTING 00
● If a part cannot be smoothly removed from the machine
by hoisting, the following checks should be made:
1. Check for removal of all bolts fastening the part to the
relative parts.
2. Check for existence of another part causing interface
with the part to be removed.
WIRE ROPES 00
1. Use adequate ropes depending on the weight of parts to
be hoisted, referring to the table below:
★ The allowable load value is estimated to be 1/6 or 1/7 of
the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
can result. Hooks have maximum strength at the middle
portion.
3. Do not sling a heavy load with one rope alone, but sling
with two or more ropes symmetrically wound on to the
load.
4. Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load with
two or more ropes, the force subjected to each rope will
increase with the hanging angles. The table below
shows the variation of allowable load (kg) when hoist-
ing is made with two ropes, each of which is allowed to
sling up to 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to 2000 kg of
total weight can be suspended. This weight becomes
1000 kg when two ropes make a 120° hanging angle. On
the other hand, two ropes are subject to an excessive
force as large as 4000 kg if they sling a 2000 kg load at a
lifting angle of 150°.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the sym-
bol.
Wire ropes
(Standard “Z” or “S” twist ropes without galvanizing)
Rope diameter Allowable load
mm kN tons
10 9.8 1.0
11.2 13.7 1.4
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
WARNING! Slinging with one rope may
cause turning of the load dur-
ing hoisting, untwisting of the
rope, or slipping of the rope
from its original winding posi-
tion on the load, which can
result in a dangerous accident
9. FOREWORD MAINTENANCE STANDARD TERMINOLOGY
00-8 WA470-6, WA480-6
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MAINTENANCE STANDARD TERMINOLOGY 00
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance
work. The following terms are used to explain the criteria.
1. Standard size and tolerance
• To be accurate, the finishing size of parts is a little different from one to another.
• To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indi-
cated.
• The above size set temporarily is called the “standard size” and the range of difference from the standard size is called
the “tolerance”.
• The tolerance with the symbols of + or – is indicated on the right side of the standard size.
•
• The tolerance may be indicated in the text and a table as [stan-
dard size (upper limit of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
• Usually, the size of a hole and the size of the shaft to be fitted to
that hole are indicated by the same standard size and different
tolerances of the hole and shaft. The tightness of fit is decided
by the tolerance.
• Indication of size of rotating shaft and hole and relationship
drawing of them.
•
Example:
Standard size Tolerance
120
–0.022
–0.126
Example:
Standard size
Tolerance
Shaft Hole
60
–0.030
–0.076
+0.046
+0
10. FOREWORD MAINTENANCE STANDARD TERMINOLOGY
WA470-6, WA480-6 00-9
122. Standard clearance and standard value
• The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range
from the minimum clearance to the maximum clearance.
• When some parts are repaired, the clearance is generally adjusted to the standard clearance.
• A value of performance and function of new products or equivalent is called the “standard value“, which is indicated
by a range or a target value.
• When some parts are repaired, the value of performance/function is set to the standard value.
3. Standard interference
• When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the
mating shaft, the difference between those diameters is called the “interference”.
• The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole
to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard inter-
ference”.
• After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in
the standard range.
4. Repair limit and allowable value or allowable dimension
• The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the
“repair limit”.
• If a part is worn to the repair limit, it must be replaced or repaired.
• The performance and function of a product lowers while it is used. A value which the product can be used without
causing a problem is called the “allowable value” or “allowable dimension”.
• If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated
from various tests or experiences in most cases, however, it must be judged after considering the operating condition
and customer's requirement.
5. Clearance limit
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts can-
not be used is called the “clearance limit”.
• If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
6. Interference limit
• The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called
the “interference limit”.
• The interference limit shows the repair limit of the part of smaller tolerance.
• If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
11. FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
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HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC
COMPONENTS 00
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur,
correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals
particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose,
it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic
oil).
Points to remember when handling electric equipment
1. Handling wiring harnesses and connectors.
Wiring harnesses consist of wiring connecting one component to
another component, connectors used for connecting and disconnect-
ing one wire from another wire, and protectors or tubes used for pro-
tecting the wiring.
Compared with other electrical components fitted in boxes or cases,
wiring harnesses are more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore, during inspection and
repair operations, they are frequently removed and installed again, so
they are likely to suffer deformation or damage. For this reason, it is
necessary to be extremely careful when handling wiring harnesses.
2. Main failures occurring in wiring harness
A. Defective contact of connectors (defective contact between male
and female).
Problems with defective contact are likely to occur because the
male connector is not properly inserted into the female connec-
tor, or because one or both of the connectors is deformed or the
position is not correctly aligned, or because there is corrosion or
oxidization of the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and contact may
become normal) by connecting and disconnecting the connector
about 10 times.
B. Defective crimping or soldering of connectors.
The pins of the male and female connectors are in contact at the
crimped terminal or soldered portion, but if there is excessive
force brought to bear on the wiring, the plating at the joint will
peel and cause improper connection or breakage.
12. FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
WA470-6, WA480-6 00-11
C. Disconnections in wiring
If the wiring is held and the connectors are pulled apart, or com-
ponents are lifted with a crane with the wiring still connected, or
a heavy object hits the wiring, the crimping of the connector
may separate, or the soldering may be damaged, or the wiring
may be broken.
D. High-pressure water entering connector
The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter the connector,
depending on the direction of the water jet. Accordingly, take
care not to splash water over the connector. The connector is
designed to prevent water from entering, but at the same time, if
water does enter, it is difficult for it to be drained. Therefore, if
water should get into the connector, the pins will be short-cir-
cuited by the water, so if any water gets in, immediately dry the
connector or take other appropriate action before passing elec-
tricity through it.
E. Oil or dirt stuck to connector
If oil or grease are stuck to the connector and an oil film is
formed on the mating surface between the male and female pins,
the oil will not let the electricity pass, so there will be defective
contact. If there is oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with compressed air and spray
it with a contact restorer.
★ When wiping the mating portion of the connector, be care-
ful not to use excessive force or deform the pins.
★ If there is oil or water in the compressed air, the contacts
will become even dirtier, so remove the oil and water from
the compressed air completely before cleaning with com-
pressed air.
13. FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
00-12 WA470-6, WA480-6
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Removing, installing, and drying connectors and wiring harnesses
1. Disconnecting connectors
A. Hold the connectors when disconnecting.
When disconnecting the connectors, hold the connectors. For
connectors held by a screw, loosen the screw fully, then hold the
male and female connectors in each hand and pull apart. For
connectors which have a lock stopper, press down the stopper
with your thumb and pull the connectors apart.
★ Never pull with one hand.
B. When removing from clips
Both the connector and clip have stoppers, which are engaged
with each other when the connector is installed.
C. When removing a connector from a clip, pull the connector in a
parallel direction to the clip for removing stoppers.
★ If the connector is twisted up and down or to the left or right, the
housing may break.
D. Action to take after removing connectors
After removing any connector, cover it with a vinyl bag to pre-
vent any dust, dirt, oil, or water from getting in the connector
portion.
★ If the machine is left disassembled for a long time, it is particu-
larly easy for improper contact to occur, so always cover the
connector.
14. FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
WA470-6, WA480-6 00-13
122. Connecting connectors
A. Check the connector visually.
Check that there is no oil, dirt, or water stuck to the connector
pins (mating portion).
Check that there is no deformation, defective contact, corrosion,
or damage to the connector pins.
Check that there is no damage or breakage to the outside of the
connector.
★ If there is any oil, water, or dirt stuck to the connector, wipe
it off with a dry cloth. If any water has got inside the con-
nector, warm the inside of the wiring with a dryer, but be
careful not to make it too hot as this will cause short cir-
cuits.
★ If there is any damage or breakage, replace the connector.
B. Insert the connector securely.
Align the position of the connector correctly, and then insert it
securely. For connectors with the lock stopper, push in the con-
nector until the stopper clicks into position.
C. Correct any protrusion of the boot and any misalignment of the
wiring harness.
For connectors fitted with boots, correct any protrusion of the
boot. In addition, if the wiring harness is misaligned, or the
clamp is out of position, adjust it to its correct position.
★ If the connector cannot be plugged in easily, remove the
clamp and adjust the position.
★ If the connector clamp has been removed, be sure to return
it to its original position.
Check that there are no loose clamps.
15. FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
00-14 WA470-6, WA480-6
123. Heavy duty wire connector (DT 8-pole, 12-pole)
Disconnection (Left figure)
While pressing both sides of locks (a) and (b), pull out female con-
nector (2).
Connection (Right figure)
A. Push in female connector (2) horizontally until the lock clicks.
Arrow: 1)
B. Since locks (a) and (b) may not be set completely, push in
female connector (2) while moving it up and down until the
locks are set normally.
Arrows: 1), 2), 3)
★ Right figure: Lock (a) is pulled down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
• Disconnection • Connection
(example of incomplete
setting of (a))
16. FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
WA470-6, WA480-6 00-15
124. Drying wiring harness
If there is any oil or dirt on the wiring harness, wipe it off with a dry
cloth. Avoid washing it in water or using steam. If the connector
must be washed in water, do not use high-pressure water or steam
directly on the wiring harness. If water gets directly on the connec-
tor, do as follows.
A. Disconnect the connector and wipe off the water with a dry
cloth.
★ If the connector is blown dry with compressed air, there is
the risk that oil in the air may cause defective contact, so
remove all oil and water from the compressed air before
blowing with air.
B. Dry the inside of the connector with a dryer.
If water gets inside the connector, use a dryer to dry the connec-
tor.
★ Hot air from the dryer can be used, but regulate the time
that the hot air is used in order not to make the connector or
related parts too hot, as this will cause deformation or dam-
age to the connector.
C. Carry out a continuity test on the connector.
After drying, leave the wiring harness disconnected and carry
out a continuity test to check for any short circuits between pins
caused by water.
★ After completely drying the connector, blow it with contact
restorer and reassemble.
17. FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
00-16 WA470-6, WA480-6
125. Handling controller
A. The controller contains a microcomputer and electronic control
circuits. These control all of the electronic circuits on the
machine, so be extremely careful when handling the controller.
B. Do not place objects on top of the controller.
C. Cover the control connectors with tape or a vinyl bag. Never
touch the connector contacts with your hand.
D. During rainy weather, do not leave the controller in a place
where it is exposed to rain.
E. Do not place the controller on oil, water, or soil, or in any hot
place, even for a short time. (Place it on a suitable dry stand).
F. Precautions when carrying out arc welding
When carrying out arc welding on the body, disconnect all wir-
ing harness connectors connected to the controller. Attach an arc
welding ground close to the welding point.
6. Points to remember when troubleshooting electric circuits
A. Always turn the power OFF before disconnecting or connecting connectors.
B. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
C. Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be gener-
ated.
D. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the
related wiring and connectors several times and check that there is no change in the reading of the tester.
★ If there is any change, there is probably defective contact in that circuit.
18. FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
WA470-6, WA480-6 00-17
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Points to remember when handling hydraulic equipment
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary
to be particularly careful.
1. Be careful of the operating environment.
Avoid adding hydraulic oil, replacing filters, or repairing the
machine in rain or high winds, or places where there is a lot of dust.
2. Disassembly and maintenance work in the field.
If disassembly or maintenance work is carried out on hydraulic
equipment in the field, there is danger of dust entering the equip-
ment. It is also difficult to check the performance after repairs, so it
is desirable to use unit exchange.
Disassembly and maintenance of hydraulic equipment should be car-
ried out in a specially prepared dustproof workshop, and the perfor-
mance should be checked with special test equipment.
3. Sealing openings.
After any piping or equipment is removed, the openings should be
sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked with a rag, there is
danger of dirt entering or of the surrounding area being made dirty
by leaking oil so never do this. Do not simply drain oil out onto the
ground, but collect it and ask the customer to dispose of it, or take it
back with you for disposal.
4. Do not let any dirt or dust get in during refilling operations.
Be careful not to let any dirt or dust get in when refilling with
hydraulic oil. Always keep the oil filler and the area around it clean,
and also use clean pumps and oil containers. If an oil cleaning device
is used, it is possible to filter out the dirt that has collected during
storage, so this is an even more effective method.
19. FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
00-18 WA470-6, WA480-6
125. Change hydraulic oil when the temperature is high.
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the cir-
cuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible
of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and
from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will
shorten the life of the hydraulic oil.
6. Flushing operations.
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is carried out twice:
primary flushing is carried out with flushing oil, and secondary
flushing is carried out with the specified hydraulic oil.
7. Cleaning operations.
After repairing the hydraulic equipment (pump, control valve, etc.)
or when running the machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning
equipment is used to remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an
extremely effective device.
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21. FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
WA470-6, WA480-6 00-19 b
12Handling Connectors Used for Engines 00
The following engines use the connectors described in this section.
• 95E-5
• 107E-1
• 114E-3
• 125E-5
• 140E-5
• 170E-5
• 12V140E-3
★ Your machine has a 114E-3 diesel engine.
Slide Lock Type 00
FRAMATOME-3, FRAMATOME-2
★ 95 – 170, 12V140 engines
• Pressure sensors and NE speed sensor
Disconnect connector (1) according to the following procedure.
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1) toward you.
3. Even if lock (L2) is pressed, connector (1) cannot be pulled toward
you if part A does not float. In this case, float part A with a small
screwdriver while pressing lock (L2), and then pull out
connector (1) toward you.
Pull Lock Type 00
PACKARD-2
★ 95 – 170, 12V140 engines
Engine Sensor
125, 170, 12V140 Intake air pressure sensor in intake manifold: PIM
125, 170, 12V140 Oil pressure sensor: POIL
95, 107, 114 Oil pressure switch
95 – 170, 12V140 Speed sensor of flywheel housing: NE
125, 170, 12V140 Ambient pressure sensor: PAMB
22. FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
00-20 b WA470-6, WA480-6
• Temperature sensors
• Disconnect the connector by pulling lock (B) (on the wiring
harness side) of connector (2) outward.
Push Lock Type 00
★ 95, 107, 114 engines
Disconnect connector (3) according to the following procedure.
1. While pressing lock (C), pull out connector (3) in the direction of
the arrow.
★ 114 engine (see graphic)
★ 107 engine (see graphic)
★ If the lock is on the underside, use flat-head screwdriver [1]
since you cannot insert your fingers.
2. While pressing up lock (C) of the connector with flat-head
screwdriver [1], pull out connector (3) in the direction of the arrow.
Engine Sensor
95 – 170, 12V140
Intake air temperature sensor in intake
manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR, etc.
Connector Sensor
BOSCH0-03 Fuel pressure sensor in common rail
23. FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
WA470-6, WA480-6 00-21 b
★ 107, 114 engines
3. While pressing lock (D), pull out connector (4) in the direction of
the arrow.
★ 95, 125 – 170, 12V140 engines
4. While pressing lock (E) of the connector, pull out connector (5) in
the direction of the arrow.
★ Injection pressure control valve of fuel supply pump: PCV
(SUMITOMO-2)
★ Speed sensor of fuel supply pump: G (SUMITOMO-3)
★ Pull the connector straight up.
Connector Sensor
SUMITOMO-04
Intake air pressure/temperature sensor
in intake manifold
Connector Sensor
AMP-3
Fuel pressure sensor in common rail:
PFUEL, etc.
24. FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
00-22 b WA470-6, WA480-6
Turn-housing Type (Round Green Connector) 00
★ 140 engine
★ Intake air pressure sensor in intake manifold (CANNON-04):
PIM etc.
1. Disconnect connector (6) according to the following procedure.
A. Turn housing (H1) in the direction of the arrow.
★ When the connector is unlocked, housing (H1) becomes
heavy to turn.
B. Pull out housing (H1) in the direction of the arrow.
★ Housing (H1) is left on the wiring harness side.
2. Connect the connector according to the following procedure.
A. Insert the connector to the end, while setting its groove.
B. Turn housing (H1) in the direction of the arrow until it clicks.
